2003 toyota matrix repair manual

Be extremely careful with this component as it can be damaged easily. Set the air flow meter aside in a safe place. Remove the small vacuum line from the nipple on the intake manifold above the throttle body. Remove the vacuum line from the auxiliary intake air control vacuum diaphragm. This diaphragm is located on the backside of the air box. Remove the large vacuum line from the engine side of the air box cover. Push Blue Tab j. Release the two air box cover clips and lift the air box cover to gain access to the VSV with the blue connector on the back side of the cover.

Remove the air box cover from the vehicle. The VSV for the auxiliary intake air control and the associated vacuum lines should come out with the air box cover. Remove the bolt holding the lower VSV bracket to the air box. Remove the Phillips head screw that holds the metal bracket to the VSV.

Remove the three bolts retaining the lower air box. Remove the lower air box from the vehicle. Remove the stock intake air duct from the engine bay. The duct is retained by one bolt and one plastic rivet.

Pry the center of the plastic rivet up with a small screwdriver, then the entire rivet should pull out. This will facilitate installation of the AEM intake pipe. Installation of AEM intake system. When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed to do so.

Place the supplied VSV bracket spacer in line with the hole exposed in the previous step. Remove the forward-most M8 bolt from the black bracket under the brake master cylinder. Thread into VSV d. Use the supplied M8 bolt to secure the assembly to the bracket beneath the master cylinder. Be sure that the spacer remains in place. Rest the upper VSV on the bracket as shown.

The rear vacuum line may need to be pulled back slightly to clear the bracket. Use one of the supplied zip ties to secure the upper VSV to the bracket. Make sure the zip tie rests in the notches in the bracket to ensure that it does not slide off. Place the supplied silicone coupler on the throttle body. Use the 3. Remove the M6 bolt that retains the front of the fuse box.

Replace the factory bolt with the supplied rubber mount. Insert the AEM intake pipe into the engine bay, filter end first. The pipe passes under the bundle of wires going to the fuse box. Install the throttle body end of the pipe into the silicone coupler, but do not tighten the hose clamps. Loosely secure the bracket to the rubber mount with the supplied M6 washer and nut.

Refer to the following diagram for proper soft mount installation. Use care to avoid damaging the insulation on either harness. Plug in the MAF sensor on the backside of the intake pipe. Remove the engine-side vacuum line from the lower VSV.

This is the line that is not connected to anything at this point. Reuse the stock spring clamp. Route the hose carefully to avoid kinks. Use the second supplied zip tie to secure the brown VSV connector to the positive battery cable. Remove two screws and one plastic rivet from the plastic splashguard under the front bumper. Make sure the air filter does not contact any part of the vehicle and tighten the hose clamp. Reassemble Vehicle a. Fender liner and Lower Front Splashguard: Install the fender liner, lower splashguard and any hardware that was removed.

NOTE: Failure to install the fender liner will result in diminished performance and increase the potential for engine damage due to water ingestion in rainy conditions. Battery: Install the battery in the reverse order of removal. If this happens turn the engine off and disconnect the battery for one minute. Reconnect the battery and restart the engine.

Affix the new Vacuum Routing Diagram to the underside of the hood. Position the inlet pipes for the best fitment. Be sure that the pipes or any other components do not contact any part of the vehicle. Tighten the rubber mount, all bolts, and hose clamps. Check for proper hood clearance. Re-adjust pipes if necessary and re-tighten them. Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly tightened.

Reconnect negative battery terminals and start engine. Let the vehicle idle for 3 minutes. Perform a final inspection before driving the vehicle.

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